Adaptor and method for facilitating the installation of walls around tubs, showers, and the like

ABSTRACT

An adapter for facilitating the installation of finished walls around bathing units, such as bathtubs, shower basins, or one-piece shower units, where the bathing units have a vertical water-retaining flange around at least part of their perimeter. The adapter includes an elongated channel and a sealing strip extending down from the channel. The adapter may be applied to the bottom edge of a section of wall board, so that the wall board enters the channel and the sealing strip points down. The wall board can then be secured to a wall adjacent the bathing unit with the sealing strip extending over the flange and abutting against a surface of the bathing unit, such as a tub deck, where it forms a water-resistant seal. The adapter forms a substantially planar surface to which finished walling materials may be applied without requiring the use of furring strips.

CROSS-REFERENCES TO RELATED APPLICATIONS

This application is a divisional of prior application Ser. No. 12/491526, filed Jun. 25, 2009.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable.

NAMES OF PARTIES TO A JOINT RESEARCH AGREEMENT

Not Applicable

REFERENCE TO A “SEQUENCE LISTING,” A TABLE, OR A COMPUTER PROGRAM LISTING APPENDIX

Not Applicable.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates generally to devices and methods for constructing finished walls around bathtubs, showers, and the like, and, more particularly, to devices and methods for facilitating the installation of finished walls by conveniently covering the water-retaining flanges found around most modern bathtubs, one-piece shower units, shower basins, and other built-in units and appliances.

2. Description of Related Art

The installation of bathtubs and showers presents particular construction challenges. Not only should the installed tub or shower be cosmetically appealing, but also it must be joined carefully with surrounding walls to prevent the seepage of water into or behind the walls.

FIG. 1 shows a typical installation of a bathing unit, such as a bathtub 110. The bathtub 110 is framed by wall studs, such as 2×4's 112, on three sides, where finished walls will eventually be constructed. The tub 110 itself includes a water retaining flange 110 a, which extends around the tub on the same three sides. The tub 110 also includes a tub deck 110 b, which usually extends around the entire tub, and a tub basin 110 c, where water is held while bathing. During installation, the tub 110 is placed on the floor, generally in a bed of mortar, and is leveled. The tub may be attached to the 2×4's 112 through the flanges 110 a using screws or nails. Then the finished walls may be applied.

Various practices have been developed for constructing finished walls around a tub 110 in an attractive and water tight manner. FIG. 2 shows a wall constructed according to a common technique. The perspective of FIG. 2 is along line 1-1 of FIG. 1. Here, it is seem that the tub 110 is placed against a wall stud 112, with the tub flange 110 a in contact with (and perhaps nailed or screwed to) the stud 112. The flange 110 a has a thickness, which varies for different models of tubs, but which is generally in the range between 0.6 cm (0.25 inch) and 1 cm (0.375 inch). A spacer, such as a plywood furring strip 210, is applied to the stud 112 just above the flange 110 a. The furring strip 210 is selected to have a thickness that matches the thickness of the flange 110 a. Together, the flange 110 a and the furring strip 210 form a planar surface upon which other layers of walling material may be applied. Generally, a section of wall board 212, such as tile backer board, is installed onto this surface and screwed or nailed through the furring strip 210 to the stud 112. The wall board 212 extends approximately down to the tub deck 110 b. A finished wall surface, such as ceramic tile 216, is then applied over the wall board 212. It may be applied using adhesive, with spaces between the tiles filled with grout 214. Where the tile 216 meets the tub deck 110 b, a flexible adhesive, such as silicone glue 218, may be applied to provide a further barrier against water seepage under the tiles 216.

If performed properly, the construction technique shown in FIG. 2 provides a lasting, water-tight installation. We have recognized, however, that this technique is expensive, both in terms of labor and materials. In particular, the need to apply furring strips 210 adds time and expense to the installation. The thickness of the flange 110 a is generally measured. Then, a furring strip is selected to match its thickness. Furring strips are applied to each stud 112 surrounding the tub or shower. If the tub or shower is not perfectly square with respect to the studs 112, the flange might not touch the studs all the way around and it may be necessary to use different thicknesses of furring strips for different studs. A great deal of measuring, cutting, and even some trial-and-error is generally needed before a satisfactory result is obtained. In addition, the walls surrounding a tub generally extend beyond the perimeter of the tub itself, and may in fact extend over the entire length or width of the bathroom. To avoid a step in the walls around the tub, which may be considered unsightly in some installations, it is often necessary to fur out not only the studs around the tub, but also those extending along the entirety of each wall against which the tub is placed.

What is needed, therefore, is an improved way of installing showers, tubs, and the like, which avoids the need to use furring strips to account for the flange and therefore costs less in terms of labor and materials.

BRIEF SUMMARY OF THE INVENTION

In accordance with one embodiment, an adapter is provided for installing a bathing unit having a water retaining flange extending up from a surface of the bathing unit to facilitate attachment to walls. The adapter includes a vertical front strip, a vertical back strip, a horizontal bottom strip joining the front strip and the back strip and forming a water impermeable channel for receiving an edge of one or more sheets of wall board, and a vertical front sealing strip extending down from the front strip for abutting the surface of the bathing unit.

In accordance with another embodiment, an adapter is provided for attaching a bathing unit to one or more surrounding walls. The adapter includes a water impermeable channel, having a front, a back, and a bottom, and extending along a length for engaging an edge of a section of wall board. The adapter further includes a sealing strip extending down from the front of the channel and having a distal edge for contacting a surface of the bathing unit and forming a seal therewith against water seepage.

In accordance with yet another embodiment, a wall is positioned at a side of a wall-integrable unit having a flange at said side extending up from a surface thereof. The wall includes a plurality of wall studs positioned vertically against the flange, a section of wall board secured to the plurality of wall studs and having a bottom edge, and an adapter positioned between the section of wall board and the wall-integrable unit. The adapter has a channel for engaging the bottom edge of the section of wall board and a sealing strip extending down from the channel, over the flange, and abutting the surface of the wall-integrable unit.

In accordance with still another embodiment, a method of installing a bathing unit having a water-retaining flange on at least one side thereof includes positioning the bathing unit against a plurality of wall studs with the flange of the bathing unit adjacent to the plurality of wall studs. The method further includes applying an adapter to an edge of a section of wall board, the adapter having a channel for engaging said edge and a sealing strip extending down from the channel away from the section of wall board, and securing the section of backer board to the plurality of wall studs with the adapter at the bottom and the sealing strip overhanging the flange.

In accordance with a still further embodiment, a method of constructing a wall at a side of a bathing unit having a water-retaining flange includes arranging a plurality of wall studs against the flange of the bathing unit. The method also includes providing a section of wall board, the section of wall board having a bottom edge, and applying an adapter to the bottom edge of the section of wall board, the adapter having a channel for engaging the bottom edge and a sealing strip extending down from the channel away from the section of wall board. The method further includes securing the section of wall board to the plurality of wall studs with the adapter at the bottom and the sealing strip overhanging the flange of the bathing unit.

In accordance with yet another embodiment, a wall includes a section of wall board having a bottom edge and an elongated adapter having a cross-section in the shape of an inverted, lowercase “h.” The adapter includes a channel within which the bottom edge of the section of wall board is disposed and a strip extending down from the channel.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 is a front, perspective view of a typical bathtub installation;

FIG. 2 is a sectional view along line 1-1 of FIG. 1, showing an arrangement of materials used to finish a wall around the bathtub of FIG. 1;

FIG. 3 is a perspective view of an adapter according to an illustrative embodiment of the invention;

FIG. 4 is a perspective view of a section of wall board with the adapter of FIG. 3 applied to its bottom edge;

FIG. 5 is a perspective view of a wall around a bathtub, using the adapter shown in FIG. 3, at an intermediate stage of construction;

FIG. 6 is a sectional view along line 1-1 of FIG. 1, showing an arrangement according to an embodiment of the invention including tile for finishing a wall around the bathtub of FIG. 1 using the adapter of FIG. 3;

FIG. 7 is a variation of FIG. 4 according to an embodiment of the invention, wherein a plastic wall covering is used instead of tile;

FIG. 8 is a flowchart showing a process according to an embodiment of the invention for installing a wall around a bathtub, or, alternatively, for installing a bathtub adjacent to an existing wall;

FIG. 9 is a perspective view of a shower basin at an early stage of construction of a finished wall around the shower basin using the adapter of FIG. 3;

FIG. 10 is a perspective view of a one-piece shower unit at an early stage of construction of a finished wall above the one-piece shower unit using the adapter of FIG. 3; and

FIG. 11 is a magnified view of the top-left of FIG. 10 showing a shower flange and the adapter of FIG. 3 used in constructing a wall above the one-piece shower unit.

DETAILED DESCRIPTION OF THE INVENTION

As used throughout this document, the words “comprising,” “including,” and “having” are intended to set forth certain items, steps, elements, or aspects of something in an open-ended fashion. Unless a specific statement is made to the contrary, these words do not indicate a closed list to which additional things cannot be added. In addition, as used herein, the term “bathing unit” refers to any appliance or furniture used for bathing people or animals, including bath tubs, shower basins, one-piece shower units, and the like.

FIG. 3 shows an adapter 300 according to an illustrative embodiment of the invention. The adapter 300 is an elongated piece having a cross-section generally in the shape of an inverted, lowercase “h.” It includes a vertical front strip 310, a horizontal bottom strip 312, a vertical back strip 314, and a vertical sealing strip 316. The front strip 310, bottom strip 312, and back strip 314 together form a channel 318 that runs the length of the adapter 300. The sealing strip 316 extends down from the channel 318 and is preferably coplanar with the front strip 310. The sealing strip has a distal edge 320. A dashed line indicates the boundary between the front strip 310 and the sealing strip 316. The adapter 300 may be used to install a finished wall around a bathtub, one-piece shower unit, or shower basin, without the need for furring strips to adjust for the thickness of the flange.

FIG. 4 shows an early stage of construction of a finished wall around a bathtub. The adapter 300 is applied to the bottom edge 410 of a section of wall board 212. The width of the channel 318 is preferably a close match to the thickness of the wall board 212, so that the adapter 300 is easily retained by friction and the wall board 212 with the adapter 300 applied can be easily moved around without the adapter 300 falling off.

FIG. 5 shows an intermediate stage of construction. The segment of wall board 212, with the adapter 300 applied, is positioned against the wall studs 112 along one side of a bathtub 110. The wall board 212 is placed against the studs 112, with the sealing strip 316 of the adapter 300 overhanging the tub flange 110 a and the distal edge 320 of the adapter 300 touching the tub deck 110 b. The wall board 212 is fixed in place using fasteners 510, such as screws or nails, which are applied through the wall board 212 and into the studs 112.

FIG. 6 shows a completed, tiled wall as a sectional view, from the same perspective as FIG. 2. A layer of grout 214 is applied over the wall board 212 and over the front of the adapter 300. The grout 114 is generally thick enough to completely obscure any step between the surface of the wall board 212 and the adapter 300. A bead of flexible adhesive, such as silicone glue 218, is preferably applied to the space between the bottom tile 216 and the tub deck 110 b. Optionally, prior to applying the grout and tiles, a bead of silicone glue may be applied directly along the line where the distal edge 320 of the adapter 300 meets the tub deck 110 b.

FIG. 7 is similar to FIG. 6, but a plastic wall covering 710 is shown, rather than tile. The plastic covering 710 is applied directly over the wall board 212 and front of the adapter 300 using adhesive. A bead of silicone is preferably applied along the line where the plastic wall 710 meets the tub deck 110 b.

FIG. 8 shows a preferred process for constructing a finished wall around a bathtub 110. At step 810, the adapter 300 is cut to the desired length, which is generally the length of the wall to which the adapter 300 is to be applied. Ends of adapter segments where one segment meets another segment at right angles may be miter cut at 45-degrees. The wall board 212 may also be cut to the desired size.

At step 812, the adapter 300 is applied to the bottom edge 410 of the section of wall board 212 (see FIG. 4), so that the bottom edge 410 sits within the channel 318 of the adapter 300.

At step 814, the section of wall board 212 with the adapter 300 in place is positioned against the studs 112. The wall board 212 is oriented with the adapter 300 down and the sealing strip 316 facing toward the center of the bathtub 110 (see FIG. 5). In this position, the sealing strip 316 extends over the tub flange 110 a and its distal edge 320 abuts the surface of the tub, i.e., the tub deck 110 b. The wall board 212 is then fixed in place using fasteners 510.

Often, because of errors in level and/or square, the distal edge 320 of the sealing strip 316 does not touch the tub deck 110 b over the entire length of the adapter 300. For example, it may touch at one end of the adapter 300 but not at the other. At step 816, this error is easily addressed simply by pushing the adapter 300 down so that it touches the tub deck 310 b at both ends and everywhere in between. It is recognized that this step may create a space between the bottom edge 410 of the wall board 212 and the bottom of the channel 318; however, there are no negative consequences to introducing this space as long as the bottom edge 410 of the wall board 412 remains at least partially inserted within the channel 318. Optionally, silicone or some other flexible adhesive may be applied along the line where the sealing strip 316 meets the tub deck 110 b.

With the wall board 212 and adapter 300 in place, a substantially flat surface is prepared that can serve as a base upon which additional wall coverings may be applied. At step 818, a surface such as tile or plastic walling material is adhered over the wall board 212 and adapter 300. If tile is used, a skim coat of grout 214 is applied and the tiles 216 are set in place. Alternatively, a plastic material may be adhered directly to the wall board 212 and over the front of the adapter 300. In either case, silicone glue 218 may be applied along the line where the finished wall covering meets the tub deck 110 b.

In the preferred embodiment, the adapter 300 is an integral piece, with the different strips molded together to form a single unit. It may be provided in standard length segments, such as 91.4 cm (6-foot) segments. The adapter 300 is made of a water-impermeable material, such as nylon. Other materials may be used, e.g., polyvinyl chloride, polypropylene, and polystyrene, to name a few. The specific type of material is not critical, provided it is water-resistant. Preferably, however, the material should be capable of extrusion molding, as the adapter 300 is economically manufactured using a standard extrusion process.

The dimensions of the adapter 300 can be varied based on the target application. For example, the width of the channel 318 is preferably matched with the thickness of wall board 212 with which the adapter 300 is intended to be used. Most wall board used in current bathtub installations is 1.3 cm (0.5 inches) thick. Therefore, the width of the channel 218 is preferably about 1.3 cm (0.5 inches), as well. Other applications require wall board that is only 0.6 cm (0.25 inch) thick. For those applications, adapters may be made with channels that are about 0.6 cm (0.25 inch) wide. Adapters of other widths can be made to accommodate other wall board thicknesses, as needed. Flanges 110 are generally in the range between 1.9 cm (0.75 inches) and 3.5 cm (1.375 inches) tall. Therefore, the height of the sealing strip 316 is preferably at least 3.5 cm (1.375 inches), such as 3.8 cm (1.5 inches), to accommodate the tallest of these flanges. Alternatively, adapters of different height can be made for accommodating different flange heights. The heights of the front strip 310 and back strip 314 are less critical; however, they are preferably tall enough to keep the adapter roughly parallel with the wall board 212 and to provide enough surface area for the adapter 300 to be frictionally retained on the wall board 212. We have found a height of 1.9 cm (0.75 inches) for the front strip 310 and a height of 2.54 cm (1.0 inch) for the back strip 314 to be sufficient.

The thicknesses of the various strips which make up the adapter 300 are determined based on different factors. All of the strips are preferably thick enough to be relatively stiff and to endure the normal stresses of installation without noticeably deforming. Also, the front strip 310 and back strip 314 should preferably be relatively thin. The front strip 310 should preferably be thin enough to avoid creating a noticeable step in the finished wall applied upon it. The back strip 314 should be thin enough to avoid spacing the wall board 212 substantially away from the studs 212. By forming the adapter 300 with an extrusion process, it is a simple matter to make the different strips different thicknesses; however, we have found that making all the strips about 0.2 cm (0.0625-inches) nicely satisfies all the design criteria when the adapter 300 is formed from any of the plastic materials identified above.

The wall board 212 used in connection with the adapter 300 may be any suitable type. For bathtubs and other applications involving water, tile backer board is preferred and is indeed required according to many building codes. Examples of tile backer board include Durock® and Hardie Backer® cement boards.

The wall studs 112 used in connection with the adapter 300 are generally wood studs, such as standard 2×4's. However, nothing prevents the studs from being constructed of other suitable materials, including steel, or of being different sizes.

The adapter 300 affords numerous benefits to builders and reduces construction time and materials. It effectively eliminates the task of furring out studs to account for the tub flange. Furring is not required, as the adapter 300 and wall board 212 themselves create a planar surface upon which tile or other walling material may be applied. Since the wall boards 212 are fixed directly to the studs 112, without an interposed furring strip, there is no unsightly step created in the wall at the border of the tub. There is also no need to fur out the entire wall in these cases to avoid such a step. The cost of the furring strips is avoided, and so is the labor associated with measuring, cutting, and placing the furring strips. The adapter 300 is also forgiving. Errors in leveling the tub, or errors in square of the wall or wall board segments, can be easily compensated simply by pressing the adapter down so that the distal edge 320 touches the tub deck 110 a along the entire length of the adapter. The adapter 300 also improves water tightness. The seal that is created between the sealing strip 316 and the tub deck 110 b provides an additional barrier against the seepage of water into the walls. By itself it forms a tight seal, and that seal can be further improved by applying silicone or some other flexible adhesive. The bottom edge 410 of the wall board 212 is also further protected against water, since it is surrounded on three sides by the adapter 300.

Having described one embodiment, numerous alternative embodiments or variations can be made. For example, the adapter 300 has been shown and described for use with bathtubs. However, it may be used to the same effect with other types of bathing units, such as shower basins and one-piece shower units.

FIG. 9 shows an example of an adapter 300 used in connection with a shower basin 910. The shower basin 910 is similar to the bathtub 110. It has a vertical, water retaining flange 910 a, a surface or deck 910 b, and a central portion 910 c. Walls are generally constructed around three sides of the shower basin 910. Each of these walls has studs 112. The adapters 300 may be used in constructing finished walls essentially as described above, with similar techniques and advantages.

FIGS. 10 and 11 show the adapter 300 being used with a one-piece shower unit 1010. FIG. 11 is a magnified view of the upper-left corner of FIG. 10. The one-piece shower unit 1010 generally includes a flange 1010 a, a surface 1010 b, walls 1010 c, and a basin 1010 d. Although the surface 1010 b is small compared to the tub deck 110 b and shower basin deck 910 b, it is generally large enough to form a surface against which the distal edge 320 of the adapter 300 may abut to form a water-tight seal. Walling materials may be applied above the one-piece shower unit essentially as described above for tubs and shower basins.

The adapter 300 is not limited to use with bathing units. It may be used with any wall-integrable unit, e.g., appliances or furniture that has a flange around at least part of its perimeter and is designed to be integrated with one or more surrounding walls. These include not only appliances or furniture that are used with water, but also others, such as built-in desks, counters, and bookshelves.

As shown and described, the adapter 300 is preferably an integral extruded piece, wherein all of its constituent strips are molded together. However, this is not required. Alternatively, the adapter may be assembled from separate pieces, which may be snapped, fastened, or adhered together.

As shown and described, tile and plastic walls may be constructed using the adapter 300. However, these are merely examples. Other types of walling materials may be used.

In addition, the process shown in FIG. 8 is merely one example of how a wall may be constructed around a bathtub using the adapter 300. Other techniques can be used. For instance, if a wall surrounding a tub or shower is longer than the width of available wall board so that multiple sheets of wall board are required, the adapter 300 can be cut to match the length of the entire wall and separate sections of wall board can be fit side-by-side into the channel 318. The precise steps of installation are limited only by the skill and imagination of the installer. According to one variant, the adapter 300 is placed loosely over the flange in its approximate final position and sections of wall board are inserted into its channel. According to another variant, one section of wall board is inserted into the channel 318 at one end of the adapter 300 and then that section of wall board with the adapter in place is positioned over the flange. Additional sections of wall board can then be added alongside the first, each inserting into the channel 318, to complete the wall.

Although FIG. 8 shows a process for constructing a finished wall around a bathtub, it is understood that the same process applies to constructing walls around other bathing units as well as around other appliances or furniture. In addition, it should be noted that, not only may the wall be constructed around the bathing unit, but also the bathing unit may be integrated with existing unfinished walls, as is commonly done for renovations. Essentially the same process may be performed in both cases.

Those skilled in the art will therefore understand that various changes in form and detail may be made to the embodiments disclosed herein without departing from the scope of the invention. 

1. A wall positioned at a side of a wall-integrable unit having a flange at said side extending up from a surface thereof, the wall comprising: a plurality of wall studs positioned vertically against the flange; a section of wall board secured to the plurality of wall studs and having a bottom edge; and an adapter positioned between the section of wall board and the wall-integrable unit, the adapter having a channel for engaging the bottom edge of the section of wall board and a sealing strip extending down from the channel, over the flange, and abutting the surface of the wall-integrable unit.
 2. The wall as recited in claim 1, wherein the channel has a width and the wall board has a thickness, and the width of the channel approximately equals the thickness of the wall board.
 3. The wall as recited in claim 1, wherein the wall-integrable unit is a counter.
 4. The wall as recited in claim 1, wherein the wall-integrable unit is a bookshelf.
 5. The wall as recited in claim 1, wherein the adapter is an extruded plastic adapter.
 6. The wall as recited in claim 1, wherein the wall-integrable unit is a bathing unit.
 7. The wall as recited in claim 6, wherein the adapter comprises a water-impermeable material.
 8. The wall as recited in claim 6, wherein the channel has a front strip that is coplanar with the sealing strip, and further comprising a plurality of tiles adhered to said wall board, front strip, and sealing strip.
 9. The wall as recited in claim 6, wherein the channel has a front strip that is coplanar with the sealing strip, and further comprising a plastic surface adhered to said wall board, front strip, and sealing strip.
 10. The wall as recited in claim 6, further comprising a flexible sealant where the sealing strip abuts the surface of the bathing unit.
 11. The wall as recited in claim 6, wherein the bathing unit is one of a bathtub, a shower basin, and a one-piece shower unit.
 12. The wall as recited in claim 6, wherein the wall board is tile backer board.
 13. A method of installing a bathing unit having a water-retaining flange on at least one side thereof, comprising: positioning the bathing unit against a plurality of wall studs with the flange of the bathing unit adjacent to the plurality of wall studs; applying an adapter to an edge of a section of wall board, the adapter having a channel for engaging said edge and a sealing strip extending down from the channel away from the section of wall board; securing the section of backer board to the plurality of wall studs with the adapter at the bottom and the sealing strip overhanging the flange.
 14. The method as recited in claim 13, wherein the adapter has a length and the sealing strip has a distal edge, and further comprising pushing the adapter down to bring the distal edge of the sealing strip in contact with a surface of the bathing unit over the entire length of the adapter.
 15. The method as recited in claim 13, further comprising applying a bead of flexible adhesive where the distal edge of the sealing strip meets the surface of the bathing unit.
 16. The method as recited in claim 13, wherein the channel has a front strip that is coplanar with the sealing strip, and further comprising adhering tiles to the wall board and over the front strip and sealing strip.
 17. A method of constructing a wall at a side of a bathing unit having a water-retaining flange, comprising: arranging a plurality of wall studs against the flange of the bathing unit; providing a section of wall board, the section of wall board having a bottom edge; applying an adapter to the bottom edge of the section of wall board, the adapter having a channel for engaging the bottom edge and a sealing strip extending down from the channel away from the section of wall board; and securing the section of wall board to the plurality of wall studs with the adapter at the bottom and the sealing strip overhanging the flange of the bathing unit.
 18. The method as recited in claim 17, wherein the adapter has a length and the sealing strip has a distal edge, and further comprising pushing the adapter down to bring the distal edge of the sealing strip in contact with a surface of the bathing unit over the entire length of the adapter.
 19. The method as recited in claim 18, further comprising applying a bead of flexible adhesive where the distal edge of the sealing strip meets the surface of the bathing unit. 